【Daily Question 200090419】Experience in DCS Configuration

In the process of engineering configuration, one never turns to seeking advice, checking documentation, or contacting the manufacturer’s technical support; instead, one tries hard to find solutions through painstaking effort, which can be quite exhausting. After the project is completed, there’s a sense of psychological satisfaction and pride – a form of vanity

First, you need to determine your approach to control—it helps to have a rough framework in place so that things are easier to handle. You also need to pay close attention to things like declarations, naming, and data types; making use of the help functions can solve many problems. The most important thing is to be meticulous! !

Most of the data entry in the configuration is done in a forced manner; there’s not much to say about it. What is tested for individuals is interlocking logic and screen optimization work; since everyone has different ways of thinking, the final outcome of the configuration varies. Therefore, it is very helpful to clarify one’s thoughts before starting the configuration, to discuss and consult with colleagues, and to determine the complex control circuits, important control circuits, monitoring points, and logical relationships first, in order to achieve a successful configuration.

I have two insights: 1. For maintenance personnel: They are concerned about accidental actions, so it’s necessary to have plans in place before carrying out any operations; backups should also be prepared. 2. For engineers, a good overall plan is essential, with attention paid to the process conditions.

I think configuring a DCS is a physically demanding task; without strength, it’s simply impossible to handle it. Patience is also necessary. At least 500 points are required – take your time. There are things like signal types, power distribution, measurement ranges, units, filtering, accumulation, and then there’s the need to create variables. It’s really complicated: for just over a hundred motors, you’ll need to create two hundred variables. Additionally, there’s the issue of flow accumulation, which requires additional accumulation variables, as well as a reset button – meaning more variables yet. Next, creating flowcharts is exhausting; it makes one’s eyes slow to react and hands uncooperative. But there’s a good solution: have someone else draw the flowchart first, someone who has just been trained, and then modify it yourself. That’s a better approach. But I must emphasize that you need to maintain quality in what you do, because imagine how you’d feel if your supervisor were to review the flowchart you’ve created, right?

Before starting the program configuration, thorough preparatory work must be carried out； The foundational work must be done properly; the points need to be set aside before work begins. There’s no problem starting the configuration work later ； We’re always annoyed by the constant addition of things in electrical and process areas. Furthermore, it is essential that configuration programs be reviewed by at least two people; since everyone thinks differently, there might be aspects that are not taken into account, and by then it will be too late if problems arise. The operator is God; the footage must be created in accordance with God’s intentions, otherwise there will be many problems. (Our operators ask questions about the instruments from time to time; some of these questions relate to the functions of the display – things like difficulties in operating it, the lack of alarm settings, or too many alarms to keep track of. It seems as though those who configured it were complete idiots)::( So, since God needs light, we should quickly provide it with some illumination.

After the DCS has been in use for a while, further modifications and additions will be made to the application software – such as improving the display visuals, adding screens that are more important for production operations, refining the control schemes, and developing advanced control software. All of these require continuous updates to the software, but care must be taken when making changes to it. Modifying application software generally involves two aspects: one is the operator’s control interface, and the other is the control program for the field station. Maintenance personnel must be aware of the impact that updates in these two areas can have on the normal production of the enterprise (for example: sudden start-ups or stoppages of motors on site during or after the update, sudden closure of electric valves that were previously open, etc.)! These impacts may already be known from the training. Taking our company as an example, during the initial stages of commissioning, we conducted tests one by one for the screen updates of the DCS system, the installation on servers, and the installation on field control stations. Updating the image simply requires overwriting the file ； Downloading the server will cause a 3-4 second pause in the data displayed on the operator interface, but it does not affect the operation of the field control station ； The on-site station control scheme can be modified and downloaded without any restrictions. Since the operation of our company’s DCS system began, there has never been any instance of the equipment starting or stopping abnormally due to modifications or updates to the application software. If, through practical use, it is found that the DCS is prone to accidental startups or shutdowns, this must be taken very seriously. Relevant rules and procedures for updating the application software should be established to ensure that such updates are carried out safely.

I have previously worked on the configuration for FOXBORO, and my experience is that: [1] it is first necessary to be well-versed in process engineering； 【2】Determine the priorities for control and acquisition.

What is the DCS configuration process? Don’t understand